Low open circuit voltage alternating current welding circuit



NOV. 11, 1952 s, o s H R 2,617,913

LOW OPEN CIRCUIT VOLTAGE ALTERNATING CURRENT WELDING CIRCUIT Filed Sept. 50, 1950 2 SHEETSSHEET 1 IN V EN TOR.

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NOV. 11, 1952 s, QESTREICHER 2,617,913

LOW OPEN CIRCUIT VOLTAGE ALTERNATING CURRENT WELDING CIRCUIT Filed Sept. 30, 1950 2 SHEETSSHEET 2 INVEN TOR. 1'! M filo/"176a Patented Nov. 11, 1952 PEREZ LQVV OPEN CIRCUIT VOLTAGE ALTERNAT- ING CURRENT WELDING CIRCUIT Sol Oestreicher, Itiilwaukee, Wis assignor to Harnischefeger Corporation, Milwaukee, Wis a corporation of Wisconsin Appiication September 3%, 1959, Serial No. 187,785

7 Ciai ns. 1

This invention relates to alternating current welders and more specifically resides in a welding apparatus having a welding transformer and an impedance associated with circuit switching elements responsive to secondary winding circuit current whereby the impedance is placed in relationship with the transformer to provide a low open circuit voltage for the secondary winding circuit.

Voltage potentials required for maintenance of adequate welding currents are necessarily, during intervals when the arc is extinguished and welding has ceased, imposed across an electrode and a work piece inassociation with the welding apparatus. The values of such potentials are such as to cause injury to the human body and from the nature of welding apparatus an operator thereof may inadvertently expose himself to the potentials. As a consequence, several designs of equipment have heretofore been employed to safeguard the operator by providing open circuit voltages below prescribed maximum safety values.

The usual alternating current welder employs a variable high leakage reactance transformer or a separate variable reactor in conjunction with a transformer as a means for attaining voltage regulation. Upon flow of welding current voltage at the electrode falls below values incurred during open circuit prior to the striking of the arc; the reactance control and the nature of a free air are contribute to this decrease in potential at the electrode. Thus, an apparatus that provides satisfactory protection to an operator must provide means whereby the electrode potential will be decreased during intervals of open circuit and it is an object of this invention to provide an improved apparatus to perform this function.

It is a further object of this invention to provide a low open circuit voltage at the welding electrode by control apparatus, both economical and simple in operation, that neither requires heavy contactors to carry large welding currents or control relays of a voltage selective type.

It is another object of this invention to provide an apparatus that may employ a welding transformer adapted for connection to power supplies of varying commercial voltage It is also an object of this invention to provide an apparatus which has its principal application to welders having a separate reactor control in the secondary circuit of a wel'ling trans former.

These and other objects will become more apparent in the description to follow.

Cal

In the description reference is made to t' e accompanying drawings which form a part her of and in which there is shown by way of illustration and not of limitation various forms in which this invention may be embodied.

In the drawings:

Fig. 1 is a schematic wiring diagram of an alternating current welder embodying this inver tion showing a welding transformer of which portion of the primary is joined in active circuit relationship only during open circuit conditions of the secondary.

Fig. 2 is a schematic wiring diagram of an alternating current welder depicting another form of this invention.

Referring now to the drawings. in there is shown a welding transformer l with primary winding 2 having a tap 3 and a secondary winding L While the tap S is depicted as a. mid-tap it should be understood that it may be placed at any desired position along the winding 2. Gne end of the winding 4 connects to a lead 5 terminating in a grounded terminal 6 attached. to a work piece 7. The opposite end of the winding 12 connects through lead 8 to an inductive reactance 9 and then through lead It to a welding electrode ll. lhe physical contact of welding electrode i i to work piece I completes the secondary winding circuit and this circuit is said to he in open circuit when the welding electrode Ii is disengaged from work piece I there is an absence of current flow.

Control circuit leads i2 and i3 terminate at one of the respective ends of each at the opposite ends of inductive reactancee. The other ends or leads l2 and [3 connect to the coil is of control relay it which coil operates the normally open contactor H3 forming a part of the relay l5. The control circuit of the apparatus is completed one contact of contactor l5 connecting to power line H through lead l8 and the other contact of contactor iii connecting to power line through lead 20, contactor coil 2i and lead 22.

The primary winding 2 of transformer i has the mid-tap terminal 3 connected to the power line is by means of a lead 23 joined to the mid-tap normally open contactor 24 and lead 25. One terminal of the winding 2 connects direct to power line it through the lead 23 as shown and the opposite end terminal connects to power line l9 through leadfil, normally closed contactor lead 29, switch and lead is l.

The closure of switch 38 impresses line voltage across the entire primary winding 2. The apparatus is designed in this circuit arrangement to induce a predetermined voltage potential in the winding 4 of a low value, which may for illustrative purposes be a value of approximately 40 volts. When the operator places the welding electrode H in physical contact with the work piece 7 a current will be allowed to flow in the secondary winding circuit and a voltage drop will appear across reactor 9 Reactor 9 is preferably a variable reactor controlled by saturation of a magnetic core through the use of an auxiliary winding not shown. Such a reactor is well known to the art, but this invention is not limited to the use of this type reactor. In response to the voltage produced across reactor 9 relay coil l will close contact l5 and impress line voltage across contactor coil 2!. Normally closed contactor 28 will open and normally open contactor 2 will close upon the energization of the coil 2 5. Lead 23 from the mid-tap 3 of the winding 2 now connects to power line l9 and the lead 2? is removed from connection therewith. Thus, power line voltage is impressed across one-half of the winding 2 and the voltage induced in secondary winding 4 is approximately doubled to 80 volts, which voltage is of sufiicient value to maintain welding currents upon striking an are between the electrode H and work piece 1.

Upon extinguishment or interruption of the arc with a resultant stoppage of current flow in the secondary circuit relay it will be deenergized and the circuit elements will assume their original positions with the open circuit secondary voltage being reduced to a safe value. Thus one-half of the primary winding 2 is utilized for welding currents and by additional impedance being placed in relationship therewith during periods of open circuit secondary the secondary voltage is decreased in value. This additional impedance, in this form of the invention, is the portion of the primary 2 between the midtap 3 and lead 21.

Referring now to Fig. 2, another form of this invention is shown. In an arrangement similar to that of Fig. 1 a welding transformer 32 has a secondary winding 33 in series connection with a reactor 34, a welding electrode 35 and a terminal 36 connecting to a work piece 3?. Power lines 38 and 39 supply voltage to a control transformer 40, line 38 connecting to one side of the primary winding 4! through lead 42, main switch it, lead 44 and lead 45, the line 39 connecting to the other side of the winding ll through lead at, main switch it and lead 41. A tap 68 that divides primary winding 4| into sections 9 and 59 connects to one end of the primary winding 5| of the welding transformer 32 through the lead 52, normally closed contactor 53, lead 5% and lead 55. The lead 55 also joins power line 39 through normally open contactor 56 and lead 51. The left, or other end as shown, of the primary winding 5! joins the primary winding ii of control transformer 4i! through leads n and 45. The left end of Winding 5! also joins power line 38 through the alternative paths of lead 45, main switch 43 and lead 42 or lead Qt, lead 58, normally open contactor 59 and lead 6d.

A power factor condenser 6i joins winding '5! in parallel relationship through leads 62, 4e, 55, 63 normally open contactor 64 and lead 55.

In the control circuit leads 66 and 6? place coil 63 of the control relay 8! in parallel connection with the reactor coil 34. Secondary W ding 69 of control transformer til forms a circuit with the coil 7E! of time delay relay 2'! through lead 72, normally open. QQntactor it Of the control relay 58, lead 14 and lead 75. Secondary winding 69 also forms a circuit with contactor coil it through the leads 12, ll, normally open contactor 18 of time relay relay ii, lead and lead 80.

Closure of the main switch 33 places line voltage across the primary winding il. A portion of this voltage is applied to the primary winding 51 of welding transformer 32 by reason of the series connection of the portion iii of the winding 4! to winding M. This portion Q9 of the winding ll acts as a voltage reducing impedance that is external to the welding transformer 32. The voltage induced in the secondary winding 33 is therefore materially lower in value than that which would occur upon connecting the primary winding 5! directly across the power lines 38 and 39. This voltage value corresponds to the 40 volts of the apparatus of Fig. 1.

As in the apparatus of Fig. 1 a voltage will appear across reactor 3 upon contact of electrode 35 with work piece 3'! so as to operate a control relay. This relay 68 will close its contacts to complete the circuit of coil '38 of time delay relay 5!. The time delay feature of relay ii is not operative upon closure, thus it will immediately close its contact '18 and the closure of contact l8 places the voltage of secondary winding 59 across contactor coil 76. Energization of coil it effects an opening of contact 53 and a closing of contacts 55, 59 and 63. The opening of contact 53 disengages primary winding 5i from the tap Q2 of winding t! and the closure of contacts 56 and 59 places the welding transformer 32 in direct connection with the power lines 33, Winding 33 now has an increased value of induced voltage similarly as that of the apparatus of Fig. 1, suitable for maintaining a welding current upon the striking of an arc.

Upon interruption of the arc and welding cur rent the control relay 68 will be de-energized, as similarly occurred in the apparatus of Fig. l. Contact it will open to disconnect time delay relay coil Hi from the control voltage of secondary winding 5d. The opening of contactor if; of the time delay relay 7| will be delayed and only upon removal of the electrode 35 from the work piece 37 for a time interval of predetermined length, which time interval extends beyond arc extinguishment encountered in sporadic welding, will contactor coil 75 be relaxed so as to al low a reduction in the induced secondary voltage of the welding transformer 32.

By use of this invention a weldin transformer may be adapted for use with more than one supply voltage. For instance, a 440 volt transformer may operate on a 440 volt line when connected as shown in Fig. 2 and may be operated on a 220 volt line when connected as shown in Fig. 1. Manufacture of welding transformers may thus be simplified by standardization of design.

I claim:

1. In an alternating current welder the combination comprising a transformer having a primary winding and a secondary winding; 2. welding electrode terminal electrically joined to one end of said secondary winding and a terminal for electrical connection to a work piece electrically joined to the opposite end of said secondary winding to form a secondary circuit therewith; a set of supply terminals adapted to be connected to a source of alternatin current; a primary circuit voltage reducing impedance; a primary circuit contactor having an actuating .coil, a set of reduced voltage contacts and a set of welding voltage contacts; reduced voltage circuit connections joining said primary winding through said reduced voltage contacts when closed and in series through said voltage reducing impedance to said supply terminals; welding voltage circuit connections joining said primary winding through said welding voltage contacts when closed directly to said supply terminals; and welding current responsive means interposed in the secondary circuit of said transformer connected to and adapted to energize the coil of said primary circuit contactor to cause said welding voltage contacts only to he closed when current is flowin in said secondary circuit and adapted to cause said reduced voltage contacts only to be closed when current is not flowing in said secondary circuit.

2. In an alternating current welder the combination comprising a transformer having a primary winding and a secondary winding; a welding electrode terminal electrically joined to one end of said secondary winding and a terminal for electrical connection to a work piece electrically joined to the opposite end of said secondary winding to form a, secondary circuit therewith; a set of supply terminals adapted to he connected to a source of alternating current; a primary circuit voltage reducing impedance; a primary circuit contactor having an actuating coil, a set of normally closed reduced voltage contacts and a set of normally open welding voltage contacts; reduced voltage circuit connections joining said primary winding through said reduced voltage contacts when closed in series through said voltage reducing impedance to said supply terminals; welding voltage circuit connections joining said primary winding through said welding voltage contacts when closed directly to said supply terminals; and switching means having contacts and a coil joined to said secondary circuit adapted to be energized by current flow in said secondary circuit to cause said contacts to be closed upon current flow in said secondary circuit and to be open when current is not flowing in said secondary circuit; and conta'ctor coil circuit connections joining said contactor coil through said switching means contacts when closed to a voltage source to energize said contactor coil, said cont'actor coil causing said normally open welding voltage contacts to close and said normally closed reduced voltage contacts to open upon energization thereof.

3. In an alternating current welder the combination comp-rising a transformer having a secondary winding and a primary winding with a tapped terminal disposed between two end terminals; a welding electrode terminal, a terminal for electrical connection with a work piece and a rector connected in series relationship with said secondary winding to form a secondary winding circuit; a set of supply terminals adapted to he joined to a source of alternating current; switchmeans having contacts and a coil connected in parallel relationship with said reacto adapted to he energized by current flowing in said secondary winding circuit and to cause closure of said contacts upon energization thereof; and a primary circuit ccntactor having a coil adapted to be joined to a voltage source for cnergization thereof through said switching means contacts, normally closed contacts adapted when closed to join the two end terminals of said primary winding to said set of supply terminals, and normally open contacts adapted when closed to connect said tapped terminal and one of said end ter- 6 minals of said primary winding to said set of supply terminals, said normally closed contacts moving to open position and said normally open contacts moving to closed position upon energization of said contactor coil.

4. In an alternating current welde the combination comprising a welding transformer having a primary winding and a secondary winding; a welding electrode terminal, a terminal for electrical connection with a work piece and a reactor in series relationship with said secondary winding to 1 orm a secondary winding circuit; a voltage control transformer having a secondary winding and a primary winding with a tapped terminal disposed between two end terminals; a set of supply terminals adapted to be connected to a source of alternating current; a control relay having contacts and a coil in parallel circuit connection with said reactor adapted to be responsive to current flowing in said secondary winding circuit to cause said contacts to open and close; circuit switch means having coil means adapted to be connected to the secondary winding of said voltage control transformer through said relay contacts when closed, a set of welding voltage 'contacts and a set of reduced voltage contacts, rc duced voltage circuit connections adapted to join said tapped-terminal and one of said end terminals of said primary winding of said voltage control transformer and said primary winding of said welding transformer in series with one another and through said reduced voltage contacts to said supply terminals; and welding voltage circuit connections adapted to join said primary windin of said welding transformer through said welding voltage contacts when closed direct to said set of supply terminals; said welding voltage contacts and said reduced voltage contacts being closed alternatively with said welding voltage contacts in closed position upon response of said relay coil to current in said secondary winding circuit.

5. In an alternating current welder the combination comprising a welding transformer having a primary winding and a secondary winding; a welding electrode terminal, a terminal for electrical connection with a work piece and a reactor in series relationship with said secondary winding to form a secondary winding circuit; a voltage control transformer having a secondary winding and a primary winding with a tapped terminal disposed between two end terminals; a set of supply terminals adapted to ibe connected to a source of alternating current a control relay 'having contacts and a coil in parallel circuit connection with said reactor adapted to be energized by current flowin in said secondary winding circuit to cause said contacts to open and close; cir cuit switch means having a set of welding voltage contacts and a set of reduced voltage contacts joined to said control relay contacts and adapted to move said reduced voltage contacts and said welding voltage contacts between open and closed positions in response to energization and deenergization of said control relay coil, reduced voltage circuit connections adapted to join said tapped terminal and one of said end terminals of the primary winding of said voltage control transformer and said primary winding of said we1ding transformer in series with one another and through said reduced voltage contacts when closed to "said sup-ply terminals and welding voltage circuit connections adapted to join said primary winding of said welding transformer direct to said supply terminals; said welding voltage contacts and said reduced voltage contacts being closed alternatively with said welding voltage contacts being closed upon energization of said relay coil.

6. In an alternating current welder the combination comprising a welding transformer having a primary Winding and a secondary winding; a welding electrode terminal electrically joined to one end of said secondary winding and a terminal for electrical connection to a work piece electrically joined to the opposite end of said secondary winding to form .a secondary circuit therewith; a Voltage control transformer having primary and secondary windings; a set of supply terminals adapted to be connected to a source of alternating current; a primary circuit contactor having an actuating coil, .a set of reduced voltage contacts, and a set of welding voltage contacts; reduced voltage circuit connections joining said primary winding of said welding transformer through said reduced Voltage contacts when closed and in series through said primary winding of said voltage control transforme to said supply terminals; welding volt-age circuit connections joining said primary winding of said welding transformer through said welding voltage contacts when closed directly to said supply terminals; and Welding current responsive means interposed in the secondary circuit of said transformer connected to and adapted to energize the coil of said primary circuit contactor to cause said welding voltage contacts only to be closed when current is flowing in said secondary circuit and adapted to cause said reduced voltage contacts only to be closed when current is not flowing in said secondary circuit.

'7. In an alternating current welder the combination comprising a transformer having a secondary winding and a primary winding with a tapped terminal disposed between two end terminals; a welding electrode terminal electrical- 1y joined to one end of said secondary Winding and a terminal for electrical connection to a work piece electrically joined to the opposite end of said secondary winding to term a secondary circuit therewith; a set of supply terminals adapted to be joined to a source of alternating current; a primary circuit contactor having an actuating coil, a set of reduced voltage contacts and a set of welding voltage contacts; reduced voltage circuit connections joining said end terminals of said primary winding through said reduced voltage contacts upon closure thereof to said supply terminals; welding voltage circuit connections joining said tapped terminal and one of said end terminals of said primary winding through said welding voltage contacts when closed to supply terminals; and Welding current responsive means interposed in the secondary circuit of said transformer connected to and adapted to energize the coil of said primary circuit contactor to cause said welding voltage contacts only to be closed when current is flowing in said secondary circuit and adapted to cause said reduced voltage contacts only to be closed when current is not flowing in said secondary circuit.

SOL

REFERENCES CKTEB The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,462,572 Gravell July 24, 1923 2,110,436 Candy Mar. 8, 1938 2,192,555 Morelisse Mar. 5, 1940 2,214,868 Welch, Jr Sept. 17, 19% 2,249,457 Catlett et a1 July 15, 1941 2,315,625 King Apr. 6, 1943 2,449,456 Corco et a1. Sept. 14, 1948 2,e86,l65 Journeaux Oct. 25, 1949 

